Device for producing a beam from a rope arrangement

ABSTRACT

Device and method for producing a beam. The device includes a rope dispenser arrangement including at least two rope sources; and a winding device. One thread sheet path from a respective rope source to the winding device is assigned to each rope source.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. §119 of European Patent Application No. 14 181 624.9 filed Aug. 20, 2014, the disclosure of which is expressly incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention relate to a device for producing a beam from a rope arrangement with a rope dispenser arrangement and a winding device.

Embodiments are described below in connection with a rope dyeing process. However, it can also be applied in other processes in which textile threads are combined to form a bundle and are in each case sectionally processed in the bundle.

2. Discussion of Background Information

In the textile industry, there are various possibilities for dyeing and processing denim fabrics. One possibility is the “rope dyeing” method. Threads, usually cotton threads, are thereby first guided together from spools of a creel to form a fiber bundle, which can also be referred to as “rope.” The rope is wound onto a beam on the so-called “ball warper.” These beams are then dyed in a so-called “rope dyeing” machine. After the dyeing, the ropes must be opened, and the threads are then wound up on a beam in an orderly manner.

Due to the ball warping process, that is, the winding-up of the rope on the ball warper to form a beam, the thread count in each rope is limited. Furthermore, only short yardage lengths are often used. This leads to the beams being only partially filled. For the subsequent further processing, many beams are accordingly necessary which are respectively only partially filled.

SUMMARY OF THE EMBODIMENTS

Embodiments of the invention is to produce a beam from a rope arrangement with high productivity.

In embodiments, a device of the type named at the outset is directed to a rope dispenser arrangement including at least two rope sources. One thread sheet path from the rope source to the winding device is assigned to each rope source.

A device of this type can also be referred to as a “long chain beamer.” It has the advantage that the threads of at least two ropes can be wound onto a beam. Accordingly, the beam produced in such a manner has at least two times the thread count, so that in a subsequent process only half of the beams are also still needed. This simplifies the management of the beams rather significantly.

Preferably, the thread sheet paths are arranged overlapping one another at least in a section directly before the winding device. Between the rope source and the winding device, the ropes are spread apart respectively to form thread sheets. These thread sheets are not wound onto the beam next to one another, but rather travel towards the beam in a similar manner. Due to the overlapping of the thread sheet paths at least directly before the winding device, it is achieved that the threads from different ropes are not present in separated sections along the longitudinal axis of the beam, but rather are “blended,” as it were. This results in a more uniform appearance of the eventual beam, so that bothersome streaks can be avoided, for example.

Here, it is preferred that the thread sheet paths travel through a common reed. This reed is arranged relatively close before the beam and thus determines the manner in which the threads from the thread sheets are wound onto the beam. If a common reed is used for the at least two thread sheets, it can be ensured that the threads from the different thread sheets are arranged in a quasi alternating manner next to one another. However, this term is to be understood relatively broadly.

Preferably, the rope source is arranged on both sides of a center line which runs perpendicular to a winding axis of the winding device. An installation space before the winding device is thus optimally exploited. For example, in the case of two rope sources, the rope sources and the thread sheet paths running from these rope sources to the winding device can be arranged in an at least approximately symmetrical manner to the center line.

Preferably, one tension-setting device is assigned to each rope source. Two tension-setting devices are respectively arranged on a shared stand arrangement. On the one hand, this saves space, since only a single stand arrangement is required for every two tension-setting devices. On the other hand, the risk of a tension-setting device rotating under the pull of the rope is relatively small if two ropes are allowed to act on sides of the stand arrangement which are opposite to one another.

Preferably, each tension-setting device has at least two rollers, so that the thread sheet path runs around each roller with multiple turns. The ropes are pulled over the rollers with a certain tension. This leads to a certain spreading-apart of the ropes already occurring on the rollers.

Preferably, a dancer device is arranged after the rollers in each thread sheet path. The dancer device regulates and compensates the tension of the thread sheets. Since a dedicated dancer device is provided for each thread sheet path, it is possible to individually regulate the tension in each thread sheet.

Preferably, a deflecting device is arranged on the stand for each thread sheet path, such that the deflecting devices are arranged at different heights in a direction perpendicular to a plane on which the thread sheet path runs. Since the thread sheets run at least approximately horizontally in the direction of gravity, the different heights can also be related to the direction of gravity. With the aid of the deflecting devices arranged at different heights, it is therefore possible to control the thread sheet paths such that the thread sheet paths can overlap one another when they run into the winding device.

Here, it is preferred that the deflecting device is arranged after the dancer device in the thread sheet path. Thread sheets for which the tension has already been set to a correct value are thus brought to overlap one another.

Embodiments of the invention are directed to a device for producing a beam. The device includes a rope dispenser arrangement including at least two rope sources; and a winding device. One thread sheet path from a respective rope source to the winding device is assigned to each rope source.

According to embodiments, the thread sheet paths may be arranged overlapping one another at least in a section immediately before the winding device. The device can also include a common reed, so that the thread sheet paths run through the common reed.

In accordance with other embodiments, the rope sources may be arranged on both sides of a center line which runs perpendicularly to a winding axis of the winding device.

Further, the device may also include a respective tension-setting device assigned to each rope source, so that at least two tension-setting devices can be arranged on a shared stand arrangement. Each tension-setting device may include at least two rollers, and herein the thread sheet path can run around each roller with multiple turns. Further, a dancer device may be arranged in each thread sheet path after the rollers. The device may also include a deflecting device for each thread sheet path being arranged on the stand, so that the deflecting devices can arranged at different heights in a direction perpendicular to a plane in which the thread sheet path runs. The deflecting devices can be arranged after the dancer device in the thread sheet path. Moreover, threads of ropes withdrawn from the rope sources can be spread apart between the deflecting devices and the winding device. Sections of the thread sheet paths between respective deflection devices and the winding device can be arranged one above the other. Further, the threads may be blended when running onto the beam.

Embodiments of the invention are directed to a method of forming a beam. The method includes withdrawing ropes comprising plural threads from at least two rope sources; guiding the withdrawn ropes along respective thread sheet paths to a winding device; and winding the plural threads of the withdrawn ropes onto the beam.

According to embodiments, the thread sheet paths can be arranged overlapping one another at least in a section immediately before the winding device.

In accordance with other embodiments, the method can also include running the thread sheet paths through a common reed.

In other embodiments, the method can include setting tension in the withdrawn ropes. The tension in the withdrawn ropes may be set by the withdrawn ropes running multiple times around at least two rollers.

According to still other embodiments, the method can also include spreading apart the threads of the ropes between respective deflecting devices and the winding device.

In accordance with still yet other embodiments of the invention, the method can also include arranging sections of the respective thread sheet paths at different heights in a direction perpendicular to a plane in which the thread sheet path runs.

Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

FIG. 1 shows a highly schematized side view of a device for producing a beam from a rope arrangement; and

FIG. 2 shows a highly schematized top view of the device.

DETAILED DESCRIPTION OF THE PRESENT EMBODIMENTS

The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

A device 1 for producing a beam from a rope arrangement includes a winding device 2 in which a beam 3, illustrated with dashed lines, is arranged. The beam 3 can be rotated around an axis 4 by a drive not illustrated in greater detail. The rope arrangement comprises at least two ropes.

A rope dispenser arrangement is provided before the winding device 2. In the exemplary embodiment, the rope dispenser arrangement has two rope sources 5, 6. Each rope source is formed by a bin in which a rope, i.e., a bundle of threads, is stored.

Above each rope source, a so-called accumulator 8, 9 is arranged on a ceiling 7 of a building. The two rope sources 5, 6 and the two accumulators 8, 9 are preferably arranged on both sides of a center line 10, which runs perpendicularly to the winding axis 4 of the winding device 2, i.e., of the beam 3.

A rope 11 is drawn off from the rope source 5 and fed to a tension-setting device 12 via the accumulator 8. The tension-setting device 12 comprises two rollers 13, 14, such that the rope 11 is wound around each roller 13, 14 with multiple turns. The rope 11 travels from the rollers 13, 14 to a dancer device 15 and from there travels to a deflecting device 16, where it is deflected in the direction of the winding device 2. Between the deflecting device 16 and the winding device 2, the rope is spread apart so that the individual threads of the rope 11 run onto the beam 3 as a thread sheet with individual threads arranged essentially next to one another. In order to arrange the threads, the winding device 2 has a reed 17.

In order to simplify the description, the designation “thread sheet path” is used in a simplified manner for the path which the threads of the rope 11 travel from the rope source 5 to the winding device 2, even if the threads of the rope 11 are still combined to form a bundle on a portion of the thread sheet path. In the thread sheet path of the rope 11, the accumulator 8, the tension-setting device 12 with the two rollers 13, 14, the dancer device 15, the deflecting device 16 and the reed 17 are thus arranged after the rope source 5.

A second rope 18 is taken from the second rope source 6 and fed to a tension-setting device 19 via the accumulator 9, which is also arranged on the ceiling 7. The tension-setting device 19 comprises two rollers 20, 21, so that the rope 18 is guided over each of the two rollers 20, 21 with multiple turns. In the direction of travel of the rope 18 after the tension-setting device 19, a dancer device 22 is arranged. After the dancer device 22, a deflecting device 23 is arranged in which the rope 18 is deflected in the direction of the winding device 2. Between the deflecting device 23 and the winding device 2, the threads of the second rope 18 are spread apart in a fan-like manner so that they are guided through the reed 17 virtually next to one another.

As can be recognized in FIG. 1, the two deflecting devices 16, 23 are arranged at different heights, so that the threads of the rope 11 and the threads of the rope 18 can be arranged overlapping one another. In FIG. 1, a section 24 of the thread sheet path of the rope 11 can be recognized above a section 25 of the thread sheet path of the rope 18. The threads of the two ropes 11, 18 are guided through the reed 17 together and wound onto the beam 3 together.

The two tension-setting devices 12, 19 are arranged on a shared stand arrangement 26. The stand arrangement 26 is only loaded by tension by the two ropes 11, 18. However, no moment around an axis running in the direction of gravity is introduced. One the one hand, the necessary installation space is thus kept small. On the other hand, the attachment is kept simple.

The two ropes 11, 18 are handled similarly until running onto the beam 3. Until entering the deflecting devices 16, 23, the ropes 11, 18 run virtually symmetrically to the center axis 10, if one disregards the height difference of the two deflecting devices 16, 23. Via the dancer device 15, 22, which are provided individually for each rope 11, 18, and the tension-setting devices 12, 19, which are likewise provided individually for each rope 11, 18, the tension in the each thread sheet, i.e., in the threads coming from the rope 11 on the one side and the threads coming from the rope 18 on the other side, can be set very accurately and can thus also equalize to one another so that all threads from the ropes 11, 18 are wound onto the beam 3 with virtually the same thread tension. Since the sections 24, 25 are arranged above one another and thus overlapping one another, the threads are blended on the beam when they run onto the beam 3. In the theoretical ideal case, it can be achieved that a thread from the rope 11 and a thread from the rope 18 are always positioned next to one another. However, practice will not always correspond to the ideal case. Despite this, both the threads from the rope 11 and also the threads from the rope 18 are distributed over the entire axial length of the beam 3 so that they are blended to a sufficient extent. In this manner, it is possible, with a low cost, to produce a beam 3 which has twice the number of threads, measured using a beam onto which threads are only wound from one rope. Accordingly, only half the beams also still need to be managed in subsequent further processing processes, which reduces the further processing cost considerably.

It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. 

What is claimed:
 1. A device for producing a beam, comprising: a rope dispenser arrangement comprising at least two rope sources; and a winding device, wherein one thread sheet path from a respective rope source to the winding device is assigned to each rope source.
 2. The device according to claim 1, wherein the thread sheet paths are arranged overlapping one another at least in a section immediately before the winding device.
 3. The device according to claim 2, further comprising a common reed, wherein the thread sheet paths run through the common reed.
 4. The device according to claim 1, wherein the rope sources are arranged on both sides of a center line which runs perpendicularly to a winding axis of the winding device.
 5. The device according to claim 1, further comprising a respective tension-setting device being assigned to each rope source, wherein at least two tension-setting devices are arranged on a shared stand arrangement.
 6. The device according to claim 5, wherein each tension-setting device comprises at least two rollers, and wherein the thread sheet path runs around each roller with multiple turns.
 7. The device according to claim 5, further comprising a dancer device being arranged in each thread sheet path after the rollers.
 8. The device according to claim 7, further comprising a deflecting device for each thread sheet path being arranged on the stand, wherein the deflecting devices are arranged at different heights in a direction perpendicular to a plane in which the thread sheet path runs.
 9. The device according to claim 8, wherein the deflecting devices are arranged after the dancer device in the thread sheet path.
 10. The device according to claim 8, wherein threads of ropes withdrawn from the rope sources are spread apart between the deflecting devices and the winding device.
 11. The device according to claim 10, wherein sections of the thread sheet paths between respective deflection devices and the winding device are arranged one above the other.
 12. The device according to claim 10, wherein the threads are blended when running onto the beam.
 13. A method of forming a beam, comprising: withdrawing ropes comprising plural threads from at least two rope sources; guiding the withdrawn ropes along respective thread sheet paths to a winding device; and winding the plural threads of the withdrawn ropes onto the beam.
 14. The method according to claim 13, wherein the thread sheet paths are arranged overlapping one another at least in a section immediately before the winding device.
 15. The method according to claim 13, further comprising running the thread sheet paths through a common reed.
 16. The method according to claim 13, further comprising setting tension in the withdrawn ropes.
 17. The method according to claim 16, wherein the tension in the withdrawn ropes is set by the withdrawn ropes running multiple times around at least two rollers.
 18. The method according to claim 13, further comprising spreading apart the threads of the ropes between respective deflecting devices and the winding device.
 19. The method according to claim 13, further comprising arranging sections of the respective thread sheet paths at different heights in a direction perpendicular to a plane in which the thread sheet path runs. 